Dunnage Conversion System Using Converging Chute and Pinch Rollers
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Solution Overview
Problem
Existing dunnage conversion machines are not ideal for all applications, as they are not compact, easy to load, and do not efficiently produce void-fill dunnage products with a high volume-to-length ratio using less sheet stock material.
Innovation Solution
A dunnage conversion machine that includes a converging chute to crumple sheet stock material and feed wheels with pinch rollers to expand slit sheet stock material, increasing its volume per unit length by stretching and thickening it, while maintaining an untorn length and preventing binding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If existing dunnage conversion machines are used to produce void-fill dunnage products, then dunnage products can be produced, but the volume per unit length ratio is low and more sheet stock material is required
Solution Approach 1:
The patent applies dimensionality change by transitioning from a two-dimensional flat sheet stock material to a three-dimensional expanded dunnage product. The expansion machine creates volumetric expansion through mechanical deformation, transforming the planar material into a volumetric structure that fills voids more efficiently. This dimensional transformation directly addresses the contradiction by increasing volume per unit length while reducing material consumption.
Solution Approach 2:
The patent utilizes parameter changes by modifying the physical state and geometric parameters of the sheet stock material during the expansion process. The material undergoes changes in thickness, density, and volumetric configuration through controlled mechanical expansion. These parameter transformations enable the same material to achieve higher volume efficiency and lower consumption, resolving the technical contradiction.
2Volume of moving object
If sheet stock material is expanded to increase volume, then volume per unit length increases, but the material may bind or tear during the expansion process
Solution Approach 1:
The patent applies dynamics by implementing a controlled, progressive expansion mechanism that moves through different stages of deformation. The expansion machine uses dynamic control of the expansion force and rate to prevent sudden stress concentrations that could cause binding or tearing. This dynamic approach allows the material to adapt to the expansion process while maintaining integrity, achieving both volume increase and reliability.
Solution Approach 2:
The patent applies preliminary action by preparing the sheet stock material before the main expansion process. The material undergoes preliminary conditioning or pre-processing that enhances its expandability and resistance to binding or tearing during the subsequent expansion. This preliminary preparation ensures the material is optimally suited for the volume-increasing transformation while maintaining structural integrity.
3Productivity
If the conversion machine is designed for high-speed production, then productivity increases, but the machine complexity and difficulty of loading increase
Solution Approach 1:
The patent applies segmentation by dividing the conversion machine into distinct functional modules or stages. This modular segmentation allows each component to be optimized for its specific function while simplifying the overall loading and operation process. The segmented design enables high-speed production through coordinated modules without proportionally increasing overall machine complexity, resolving the contradiction between productivity and device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The machine produces a three-dimensional dunnage product with increased volume and lower density per unit length, effectively filling voids in packaging containers and providing cushioning, thus protecting articles during shipment.
Implementation Method 1
the feed wheels and the pinch rollers cooperate to apply tension in the feed direction to the sheet stock material traveling therebetween to expand the sheet stock material
Data Source
AI summary
A dunnage conversion system for expanding an unexpanded slit sheet stock material to form an expanded dunnage product. The dunnage conversion system includes a converging chute to inwardly gather laterally-extending edges of sheet stock material towards one another, causing random crumpling of the sheet stock material to form a modified ply. The conversion system also includes feed wheels that advance the modified ply through the converging chute and pinch rollers that cooperate with the feed wheels to expand the modified ply traveling between the feed wheels and the pinch rollers to form a dunnage product. The expanded dunnage product is expanded both in a longitudinal feed direction and in thickness as compared to the unexpanded slit sheet stock material, and thus is a three-dimensional product having increased volume and lower density per unit of length as compared to the unexpanded slit sheet stock material.